Process for making printing matrix



May 3, 1966 J. G. MAST PROCESS FOR MAKING PRINTING MATRIX 2 Sheets-Sheet1 Original Filed May 8, 1962 lT a 5 n a 7 u m 8 n m a m a P g 2 0 J J 4j a W y 3, 1966 J. G. MAST 3,249,042

PROCESS FOR MAKING PRINTING MATRIX Original Filed May 8, 1982 2Sheets-Sheer. 2

jnderafoz yysozye fihsi United States Patent 3,249,042 PROCESS FORMAKING PRINTING MATRIX J. George Mast, 9 N. Kenilworth, Mount Prospect,Ill. Original application May 8, 1962, Ser. No. 193,235, now Patent No.3,179,988, dated Apr. 27, 1965. Divided and this application Aug. 12,1964, Ser. No. 389,088 Claims. (Cl. 101-17) This is a division of mycopending application having Serial No. 193,235, filed May 8, 1962, andissued as U.S. Patent 3,179,988 on April 27, 1965.

This invention relates to an improved matrix of a type used in theprinting industry. More particularly it relates to an improved matrixand to a process of producing matrices for producing printing slugs.

The most widely used and conventional type matrix is generally made ofporous paper and after it has been suitably impressed by high pressureswith the detail of an engraving, it is placed in a holder or stickwhereupon lead under pressure is poured into the matrix and the printingsing or plate is thus obtained. Such matrices, or as they are known inthe art, mats, have distinct disadvantages in that they deterioraterapidly and can only be used for one casting. Also they readily absorbmoisture and therefore are unstable as to size because of expansion andshrinkage. Different mats have been tried wherein a thin foil of metalwould be bonded to a backing plate of fibrous material. Such aconstruction was found unsatisfactory since the foil could not withstandthe high pressures of forming in the process of impressing the engravingand thus tearing and destruction would ensue. Many other variations havebeen tried without success. Another distinct disadvantage with papermatrices was the fracture of the paper fibers during the embossing whichcaused the ends of the fibers to form pit marks in the slugs which wereproduced from the paper matrix.

It is therefore a prime object of this invention to provide an improvedmatrix which can be used over and over again and which will continue towithstand the high pressures of lead pouring.

It is another object of this invention to produce a matrix which willnot absorb moisture, which will not be porous and which will not shrinkor expand to any substantial degree.

It is a further object to produce a matrix from a soft metal, the metalbeing sufficiently strong to withstand high pressures of pouring, andhigh heat, and being so disposed as to be readily impressed under highpressures with the detail of a steel photo-engraving plate disposed in apunch press or roller press.

Still another object of the invention is to provide a matrix that can beinexpensively produced in a high pressure press operation.

Another object is to provide an improved matrix consisting of two layersof identical material of certain dimensions, one layer providing thepattern surface, the other layer providing the backing or controlsurface during the impression of the pattern surface by a steel photoengraving by means of high pressures.

A further object is to provide an improved process of producing a matrixincluding the steps of using the same in the formation of a castprinting plate or slug.

Another object is to provide an improved matrix formed of very softsubstantially pure aluminum having sufiicient ductility and tensilestrength to be impressed with an embossing die under high pressuresresulting in a strong durable, non-porous matrix having substantiallyperfect detail.

Another more specific object is to provide an improved matrix andprocess of manufacture where the "ice matrix consists of a flattenedtube just prior to the impressing operation.

These and further objects will become more readily apparent from areading of the specification when examined in connection with theaccompanying sheet of drawing, in which:

FIGURE 1 is a plan view of a steel photo-engraving having a certaindetail;

FIGURE 2 is an end view of the photo-engraving of FIGURE 1; 1

FIGURE 3 is a plan view of a blank of aluminum sheet used in making animproved matrix;

FIGURE 4 is a plan view showing the blank of FIG- URE 1 folded toprovide two laminations or contiguous layers connected together at thefolded edge;

FIGURE 5 is cross-sectional view taken along the line S5 of FIGURE 4;

FIGURE 6 is a side elevational View of a folded matrix blank in positionin a punch press with the blank disposed on top of a photo-engravingready for the impression or forming operation;

FIGURE 7 is a plan view of the folded blank, in an unfolded positionshowing the pattern or detail side and the bottom or backing side afterimpressing operation;

FIGURE 8 is a plan View of the blank which has been impressed in anunfolded position showing the underneath side of the pattern surface andthe normally contiguous side of the backing layer or lamination;

FIGURE 9 is a cross-sectional view through a matrix, after it has beenimpressed showing the raised and compressed portions providing thedesired detail;

FIGURE 10 is a perspective view showing the matrix seated within astick, which in turn is utilized in a machine (not shown) for producingcast printing slugs;

FIGURE 11 is a modification which shows a perspective of an aluminumtube which may be of the same length as the desired matrix; and

FIGURE 12 is a perspective View which shows the aluminum tube of FIGURE11 flattened to provide a blank for forming a matrix.

Referring now to the drawing, FIGURE 1 shows a photo-engraving 10 whichis constructed of steel. The engraving 10 comprises a thin steel platehaving suitable projections 11 forming the desired detail. The edges 12of the engraving are tapered. In FIGURE 3, a blank of flat sheetaluminum is designated at 13 the thickness of which is .016 of an inch.The material found to be most desirable is substantially 99% aluminumwith remainder impurities. The aluminum sheet used has been annealedafter it has been produced to make it exceptionally soft. It thus has asoftness designation known in the aluminum trade as 0. This designationis found in the book known as Sheet and Plate product informa tionsecond edition, January 1958, copyrighted by Kaiser Aluminum & ChemicalSales, Inc. The designation in the trade of this substantially purealuminum is 1100, and is known as being relatively soft and ductile.This mate rial has a tensile strength of 13,000 p.s.i. and yieldstrength of 5,000 p.s.i.

FIGURE 4 shows the aluminum sheet 13 folded into two substantiallyidentical layers providing a matrix blank 14 having an upper layer 15providing a detail or pattern surface 16 and having an underneathsurface 17. The layer 15 is connected to a lower layer 18, by means ofthe folded portion 19, the said layer 18 having a surface 20 contiguouswith the surface 17, and a bottom surface 21.

FIGURE 6, shows the photo-engraving 10 positioned within a slot 22 of abottom support 23, suitably supported in a conventional punch press (notshown). The sides of the slot 22 are tapered to receive the taperededges 12 of the engraving to securely hold the same in position. Aforming punch or die is designated at 24, the same being attached to theupper ram of a punch press (not shown). The upper forming member 24includes a fiat surface 25 which engages the matrix 14 upon loweringtheram. Stops 26 on themember 24 limit the downward travel of the member24. The stops have a dimensional height of .024 inch, which limits thedownward travel of the member 24, the stops engaging the upper surfaceof the support -23, so that the edges of the matrix after forming have adimensional thickness of .024 inch as shown in. FIGURE 9'.

The tonnage utilized in the formingoperation may vary from 30 tons to 70tons, dependingon the pattern detail as desired. As the forming member24 compresses the matrix'14, the detail 11 of the photo-engraving 10 isimpressed in the matrix to provide positive-detail in the form ofprojections or depressions which form the pattern for the subsequentslug to be cast. The projections of the pattern, are of course thedepressions of the cast slug, and the depressions of the pattern ontheother hand are the projections of the cast slug which do theimprinting.

The detail projections on the matrix of FIGURE 9, are designated at 30,and the depressions are designated at 31. The maximum projections of thematrix are designated at 32, and these form the relief which providesthe deep depressions within the slug which in no manner print, butseparates thedetail from the edges of the matrix or slug. The maximumheight of the projection 32 fromthe deepest depression is .030 inch asshown in FIGURE 9, and the maximum depression is .024 inch fromthebottom surface 21 of the matrix. As shown in FIGURE 9, the topsurface 16 has the projections 30 and depressions 31 in sharp detail,whereas in the second sheet 18 they are of lesser fine detail.

In the forming operation the two layers of aluminum of the matrix playan important part. Theymust definitely be connected, at least on oneedge as shown by the folded portion 19, or they may be stacked orriveted together so that they cannot move'laterally relative to eachother. A single layer of aluminum is ineffective since the detailproduced is ineffective. The secondlayer ofthe matrix as here shown actsto cushion the forming operation, and by supporting the: top layer,keeps the same from spreading indiscriminately and thus controls theforming operation. In other words the second layer controls and cushionsthe flow of the metal to produce a sharp detail on the pattern surfaceor face of the matrix.

The aluminum sheet used must be thicker than foil and of high tensilestrength so that it can stretch and form without tearing during the highpressures encountered during-the impression of the photo-engraving. Ithas been found that the desirable limits are .013 inch up to andincluding .018 inch, the aluminum having the desirable softness of atype as aforementioned in 1100 material with a temper.

The surfaces of the aluminum blank should be flat, without anyindentations. In other words, the surfaces should be smooth so that thecontiguous edges of the sheet are absolutely flat as well asthe patternsurface 16. Indentations on the surface to be embossed are detrimentalsince they leave markings in the completed mat, which then aretransferred to the slug and cause imperfect printing.

The edges of the matrix as shown in FIGURE 9 have a total thicknessafter impression of .024 inch. The material as specified before forminghas a total thickness of .032 inch. Thus the material upon impressionflows laterally, or becomes larger in over-all dimension. In otherwords, the thickness decreases and the over-all dimension expands. Thusa matrix can be made by the high production means afforded. by a punchpress type of production.

The matrix thus has now been produced and is ready to produce the castslug. It is placed in the composing stick shown in FIGURE 10, anddesignated at 33. This stick 3 3, is placed in a suitable conventionalcasting machine (not shown) and lead in fluid form under pressure ispoured into the cavity 34, whereupon hardening the casting plate (orslug), (not shown), is formed. The lead is poured at a temperature ofapproximately 580 or more at a pressure of approximately from 400 to 600lbs. per square inch. Generally the more precise the detail the greaterthe pressure'is required.

The matrix because of its sharp detail and durability will be usable formany pourings. Since it is not suscepti-- ble to absorption ofmoisture,shrinkage and expansion is no problem. Another very important advantageof the aluminum matrix is that the material, after impression by theengravin'gplate or die, work hardens to a temper of H12, whichinthe artis knownas quarter hard. This is advantageous since it adds strengthandat 35; and is formed of a tube 36 of aluminum, which.

is flattened by suitable pressure means, such as a press, rollers, etc.(not shown), to the flattened condition shown in FIGURE 12. The matrix35 is thus connected at both sides by edges 37'. The matrix 35 isotherwise identical-in dimensions and specifications as the matrix 14and the same reference characters will apply. In complete form it willappear as the matrix 14 in FIGURE 9, with the exceptionboth edges arejoined, instead of only one.

Another distinct advantage of this aluminum mat is that it readilydissipates heat .du-ring the casting of the slug. This is verydesirable. On the other hand paper mats, insulate and are very poor-indissipatingthe heat thus causing difliculty'in casting.

Thus the objects of the invention have been fully achieved and itmust beunderstood that changes and modifications may be made without departingfrom the spirit ofthe invention 'or from the scope .of the appendedclaims.

I claim:

1'. A method of producinga matrixcomprising the steps of placing firstand second sheets of similar or like ductile metals connected along atleast one edge in superimposed contiguous relation one over the other topro vide first and second opposed surfaces, placing said matrix on a.steel engraving plate having projectionsand depressions providingprinting detail, forcing said plate and said matrix together under'highpressures whereby the matrix, is reduced in-thickness and fine printingdetail is formed by the flow of'rnaterial in the first surface toprovide a pattern surface, said second surface having similardepressions and projections of lesserfine'detail.

2. A method 'inaccordance with claim 1 wherein both of said plates'areforced against the'matrix by a metal forming press means.

3. A method of producing a matrix in accordance with claim 1, whereinthe sheets consists 'of'aluminum and are of equal thickness.

4. A meth'odin accordance with claim'l, wherein the matrix comprises ablank of metal bent over on itself to provide the first and secondsheets.

5. A method inaccordance with claim 1, wherein the matrix comprises ametal tube flattened to form said first and second sheets.

References Cited by the Examiner UNITED STATES PATENTS 752,846 2/1904Leslie 101401.1 1,377,513 5/1921 Novotny 101401.2 2,085,740 7/1937 Davis101-401.1

FOREIGN PATENTS 556 1954 Great Britain.

DAVI D KLEIN, Primary Examiner.

HERMAN I STRNISHA, Assistant Examiner.

1. A METHOD OF PRODUCING A MATRIX COMPRISING THE STEPS OF PLACING FIRSTAND SECOND SHEETS OF SIMILAR OR LIKE DUCTILE METALS CONNECTED ALONG ATLEAST ONE EDGE IN SUPERIMPOSED CONTIGUOUS RELATION ONE OVER THE OTHER TOPROVIDE FIRST AND SECOND OPPOSED SURFACES, PLACING SAID MATRIX ON ASTEEL ENGRAVING PLATE HAVING PROJECTIONS AND DEPRESSIONS PROVIDINGPRINTING DETAIL, FORCING SAID PLATE AND SAID MATRIX TOGETHER UNDER HIGHPRESSURES WHEREBY THE MATRIX IS REDUCE IN THICKNESS AND FINE PRINTINGDETAIL IS FORMED BY THE FLOW OF MATERIAL IN THE FIRST SURFACE TO PROVIDEA PATTERN SURFACE, SAID SECOND SURFACE HAVING SIMILAR DEPRESSIONS ANDPROJECTIONS OF LESSER FINE DETAIL.